Safety Recall T34/NHTSA 17V-371 PHEV Power Inverter Module (RC-T34-17)

A. RECORD VEHICLE MILEAGE

Record on the work order the vehicle mileage from the odometer in the instrument panel cluster. Is the vehicle mileage 700 miles or less?

• YES, vehicle mileage is 700 miles or less  . Vehicles with 700 miles or less are to have the PIM replaced and have the PCM, BPCM, OBCM, and PIM reprogrammed with new software. Proceed to section B. Power Inverter Module (PIM) Removal. PIM replacement must be performed by a PHEV trained technician. 
• NO, vehicle mileage is greater than 700 miles  . Vehicles with more than 700 miles are to only have the PCM, BPCM, OBCM, and PIM reprogrammed with new software, do not replace PIM. Proceed to section D. Reprogram Power Inverter Module (PIM). 

PIM replacement must be performed by a PHEV trained technician. 

B. POWER INVERTER MODULE (PIM) REMOVAL

1. Familiarize yourself with all HIGH-VOLTAGE SAFETY PROCEDURES related to personal safety and vehicle safety associated with working on a Plug-In Hybrid Electric Vehicle (PHEV). Prepare the work area according to those PROCEDURES.
2. Disconnect any Electric Vehicle Service Equipment (EVSE) or charging equipment, move the front seats forward for access to the high voltage battery service disconnect cover, turn off the ignition, remove the keys, open the hood and leave the vehicle doors open.
3. Inspect all orange high-voltage cables, and all high-voltage components labeled with the high-voltage symbol for physical damage. If damage is present, extra caution must be taken to avoid contact with uninsulated high-voltage. Do not insert probes, tools, objects or fluids into damaged high-voltage cables or components.
   NOTE: Because the high-voltage battery is used to charge the 12-volt battery via the Auxiliary Power Module (APM), disconnecting the 12-volt battery negative cable will not power down the 12-volt system. The following procedure must be performed before any repairs, disassembly, or testing requiring 12-volt power down are carried out.
   NOTE: Even though the high-voltage battery manual service disconnect is removed during the 12-volt Power Down procedure, the 12-volt Power Down procedure will NOT safely and reliably power down the high-voltage system. If any high-voltage components are to be accessed, disconnected or tested, the High-Voltage Power Down procedure must first be carried out.
4. Remove and save the 12-volt Power Distribution Center (PDC) cover (Figure 1).
5. Remove and save the nut securing the positive battery cable, then disconnect the positive battery cable from the 12-volt PDC (Figure 2).
6. Cover the positive battery cable terminal with protective cover 10084 (Figure 3).
7. Lift the carpet away from the high-voltage manual service disconnect access cover (Figure 4).
8. Remove and save the four screws securing the high-voltage manual service disconnect access cover to the floor then remove and save the cover (Figure 5).
9. Depress the lever release latch firmly. With the latch fully depressed, rotate the lever upward. The lever will stop at the 45° position (Figure 6).
   NOTE: At this stage, the High Voltage Inter-Lock (HVIL) connection has been broken and the circuit is de-energized.
10. Depress the locking tab and continue to rotate the lever to the end of travel, 90° position (Figure 7).
11. Pull straight up on the service disconnect lever to disengage and remove the high-voltage manual service disconnect from the receptacle (Figure 8).
    NOTE: Make sure the location of the high-voltage manual service disconnect is always known after removal. It is best practice to place the high-voltage manual service disconnect in a highly visible location when removed.
12. Cap the receptacle on the high-voltage battery with the appropriate cover found in safety cover set 2035100081 to prevent foreign objects from entering the receptacle (Figure 9).
13. Check the 12-Volt system at the Power Distribution Center (PDC) with a multimeter to assure that there is less than 1-Volt present. If so, the 12-volt electrical system is now powered down.
    NOTE: A small voltage reading of less than 1-Volt is to be expected as system capacitors slowly discharge. If more than 1-Volt is still present, contact the STAR Center for service support before proceeding.
14. Disconnect the fresh air makeup hose from the air cleaner body (Figure 10).
15. Disconnect the wire harness connector from the Inlet Air Temperature (IAT) sensor (Figure 10).
16. Loosen the clean air hose clamp and disengage the clean air hose from the resonator (Figure 10).
17. Loosen the cover screws and remove the air cleaner housing cover (Figure 10).
18. Remove the air cleaner element (Figure 11).
19. Loosen the duct clamp and pull the air inlet duct straight up to disengage the locating pins from the rubber mount sockets (Figure 12).
20. Disengage the air cleaner body locating pins from the rubber mount sockets then remove and save the air cleaner body (Figure 12).
    NOTE: Use of an insulation tester such as the Fluke Multi-meter 126-1587 is recommended for PHEV circuit testing. Perform the multi-meter functionality tests per the manufacturer's directions. Verify the multimeter is operating correctly by measuring voltage from a known good power source, such as the vehicle's 12-volt battery. If at any point during the procedure, the multi-meter settings are changed, or the probes are repositioned in the meter, verification with a known good power source must be repeated.
    WARNING: High voltage Personnel Protection Equipment (PPE) Protector Glove Set 10152B must be worn for the following steps. Gloves must be worn until the PIM voltage is measured and verified to be near 0-volts.
21. Loosen two captive screws then remove and save the single High Voltage Inter-Lock (HVIL) connector from the PIM cover (Figure 13).
22. Loosen five captive screws then remove and save the PIM cover (Figure 14).
    NOTE: Always observe these precautions prior to taking a high-voltage measurement:

    • Have known good test leads.
    • Set the range to no decimal points.
    • Read a known good low-voltage source first.
    • Always wear high-voltage gloves and safety glasses.
23. Measure the voltage between the positive and negative high voltage terminals. Also, measure the voltage between each high voltage terminal and chassis ground (Figure 15). The measured voltage should be near 0-volts.
    • If the voltage measured is near 0-volts, the high-voltage components are safe to work on with the exception of the high-voltage battery internal components.
    • If the voltage is not near 0-volts, an internal condition exists within the high-voltage battery that is preventing it from being powered down. Do not attempt to carry out repairs on any of the vehicle's high-voltage components or wiring. Contact the STAR Center for service support  .
24. Measure and record the isolation resistance at the Power Inverter Module (PIM) between the positive high voltage terminal and chassis ground, also between the negative high voltage terminal and chassis ground. The measured isolation resistance should be greater than 1.1 MΩ and less than 10 MΩ. These isolation resistance values will need to be compared with those taken during High-Voltage Power-Up to verify the integrity of the repair.
25. Raise and support the vehicle.
    CAUTION: Do not position hoisting device on any suspension component, including the front or rear suspension crossmembers. Do not hoist on the front and rear bumpers, the lower radiator crossmember, the front engine mount or any part of the underbody other than the identified lifting areas.
26. Remove the four black screws (two per side) attaching the wheelhouse splash shields to the front belly pan (Figure 16).
27. Remove the six black front screws (Figure 16).
28. Remove the two push-pin fasteners (Figure 16).
29. Remove the eight silver screws (Figure 16).
30. Remove the front belly pan (Figure 16).
31. Remove and save the four black screws (two per side) attaching the wheelhouse splash shields to the engine belly pan (Figure 17).
32. Remove and save the push pin fastener (Figure 17).
33. Remove and save the ten silver screws then remove and save the engine belly pan (Figure 17).
34. Lower the vehicle.
35. Loosen the cap on the power electronics cooling system pressurized coolant reservoir to relieve any residual pressure (Figure 18):
    1. Rotate the cap counterclockwise to align the slots (Figure 18).
    2. Insert a screwdriver into the slots and continue rotating the cap counterclockwise (Figure 18).
    CAUTION: Do not allow coolant to come in contact with any high voltage component electrical connections. Engine coolant will create a conductive path and cannot be effectively removed resulting in a loss of isolation and replacement of the contaminated high voltage component.
36. Place a suitable container under the PIM coolant inlet and outlet hoses.
37. Using suitable hose-pinching pliers, clamp-closed the coolant inlet and outlet hoses near the PIM (Figure 19).
38. Loosen the clamps and remove the coolant inlet and outlet hoses from the PIM. Cap the coolant hose ends and the nipples on the PIM (Figure 19).
39. Remove and save the bolts from the engine cover (Figure 20).
40. Pull upward on the engine cover to release the cover grommets from the ball studs and remove the engine cover (Figure 20).
41. Remove and save the bolt from the resonator (Figure 21).
42. Pull the resonator straight up to release the resonator grommet from the ball stud on the right cylinder head cover. Disengage and remove the resonator from the throttle body inlet (Figure 21).
43. Remove and save the high voltage battery cable terminal bolts (Figure 22).
44. Loosen the two captive screws securing the high voltage battery cable connector housing to the PIM (Figure 22).
45. Remove and save the nut securing the high-voltage battery cable retainer (Figure 23).
46. Disengage the high voltage battery cable connector housing from the PIM, (Figure 23).
    NOTE: Ensure the wave washers remain on the high voltage battery cable connector housing during removal of the cables from the PIM housing. If the wave washers are dislodged, reseat them (Figure 24).
47. Cover the high-voltage cable terminals with protective covers 10084 (Figure 24) then reposition the high voltage harness to a safe location.
48. Disengage the four wire harness retainers securing the Electric Air Compressor (EAC) wire harness to the PIM (Figure 25).
49. Disengage the wire harness retainer securing the EAC wire harness to the harness support bracket (Figure 26).
50. Slide the EAC electrical connector locking clip rearward (Figure 26).
51. Depress the EAC electrical connector release tab while pulling the EAC electrical connector rearward to disconnect the EAC electrical connector from the PIM (Figure 26). Reposition the EAC wire harness to a safe location.
52. Remove and save the two nuts and one bolt securing the harness support bracket, then remove and save the bracket (Figure 26).
53. Remove and save the stud-nut securing the chassis ground cable to the PIM. Reposition the chassis ground cable from the PIM (Figure 27).
54. Unlock and disconnect the processor wire harness connectors from the PIM (Figure 28). Reposition the connectors.
55. Remove and save the bolt securing the chassis ground cable to the PIM (Figure 29). Reposition the chassis ground cable.
56. Disengage the three retainers securing the engine wire harness to the PIM heatshield then reposition the engine wire harness (Figure 30).
57. Remove and save the four screws from the PIM heatshield then remove and save the PIM heatshield (Figures 30 and 31).
58. Loosen the two captured screws then remove and save the HVIL connector from the PIM e-Motor terminal cover (Figure 32).
59. Loosen the four captured screws then remove and save the PIM e-Motor terminal cover (Figure 33).
60. Loosen the six captured e-Motor electrical terminal bolts to prepare for PIM removal (Figure 34).
61. Carefully position a floor jack under transmission to support the transmission.
62. Remove three bolts from the left side transmission mount bracket (Figure 35).
63. Lower the transmission approximately one inch.
64. Remove and save the five bolts securing the PIM to the transmission housing (Figure 36).
65. Remove and save the PIM from the transmission housing (Figure 36).
66. Remove and discard the PIM carrier gasket (Figures 37 and 38).
67. Destroy and discard, the PIM, e-Motor terminal cover, both HVIL connectors, and PIM cover.
68. Proceed to section C. Power Inverter Module (PIM) Installation 

C. POWER INVERTER MODULE (PIM) INSTALLATION

The following covers must be removed from the new PIM to prepare the new PIM for installation:

• Shipping Conver
• HVIL Connector
• E-Motor Terminal Cover
• PIM Cover

1. Install the new  PIM carrier gasket to the transmission housing while ensuring that that gasket locator pins are seated in the holes on the transmission housing (Figures 37 and 38).
   NOTE: Ensure that the gasket locator pins are facing the transmission and are fully seated into the holes in the transmission housing (Figure 38). If the gasket is not installed correctly, water will enter the high voltage area and cause a loss of mobility.
   CAUTION: Do not install a PIM that is missing any of the six captured e-Motor electrical terminal bolts (Figure 39). If any fastener is missing and not accounted for in the dunnage, the PIM must be returned to Mopar as there is a risk it is inside the PIM.
2. Install the new  PIM to the transmission housing with five bolts. Tighten the bolts in the sequence shown to 62 N.m (46 Ft. Lbs.) (Figure 40).
3. Using the floor jack, raise the transmission and install the three bolts to the LH engine (transmission) mount bracket. Tighten the bolts to 105 N.m (77 Ft. Lbs.) (Figure 35). Remove the floor jack from the vehicle.
4. Tighten the six captured e-Motor electrical terminal bolts to 11 N.m (97 In. Lbs.) (Figure 34).
5. Install the new  PIM e-Motor terminal cover to the PIM. Tighten the four captured screws to 7.8 N.m (69 In. Lbs.) (Figure 33).
   CAUTION: Ensure the cover gasket is properly seated in the groove prior to assembly onto the PIM. If not seated properly, the gasket will be damaged when the cover fasteners are tightened.
6. Install the new  High Voltage Interlock (HVIL) connector to the PIM e-Motor terminal cover. Tighten the two captured screws to 7.8 N.m (69 In. Lbs.) (Figure 32).
7. Install the PIM heatshield with four screws. Tighten the screws to 11 N.m (97 In. Lbs.) (Figures 30 and 31).
8. Position the engine wire harness and engage the three wire harness retainers to the PIM heatshield (Figure 30). New  wire harness retainers are supplied with the PIM kit to replace any damaged retainers.
9. Position the chassis ground cable to the PIM then install and tighten the chassis ground cable bolt to 9 N.m (80 In. Lbs.) (Figure 29).
10. Connect and lock the processor wire harness connectors to the PIM (Figure 28).
11. Position the chassis ground cable to the PIM. Install the chassis ground cable stud-nut and tighten to 9 N.m (80 In. Lbs.) (Figure 27).
12. Install the harness support bracket to the transmission mount with two nuts and one bolt. Tighten the bolt and nuts to 115 N.m (85 Ft. Lbs.) (Figure 26).
13. Connect the Electric Air Conditioning (EAC) wire harness electrical connector to the PIM (Figure 26).
14. Slide the EAC electrical connector locking clip forward to lock the EAC electrical connector to the PIM (Figure 26).
15. Position the wire harness and engage the wire harness retainer securing the EAC wire harness to the transmission mount bracket (Figure 26).
16. Position the wire harness and engage the four EAC wire harness retainers to the PIM (Figure 25).
    NOTE: New wire harness retainers are supplied with the PIM kit to replace any damaged retainers.
17. Remove the protective covers 10084 from the high-voltage cable terminals (Figure 24).
    NOTE: Ensure the wave washers remain on the high voltage battery cable connector housing during installation of the cables to the PIM housing. If the wave washers are dislodged, reseat them (Figure 24).
18. Install the high voltage battery cable connector housing into the PIM and tighten the two screws to 11 N.m (97 In. Lbs.) (Figures 23 and 22).
19. Install the high voltage battery cable terminal bolts and tighten to 25 N.m (18 Ft. Lbs.) (Figure 41).
    CAUTION: Tightening of high voltage battery cable terminal bolts to proper torque specification is critical otherwise damage to PIM and/or high voltage battery cables may occur.
20. Position the high voltage harness to the harness support bracket and tighten the nut to 11 N.m (97 In. Lbs.) (Figure 23).
21. Lubricate the rubber grommet on the resonator with Mopar® Rubber Bushing Installation Lube.
22. Install the resonator to the throttle body inlet. Push the resonator down onto the ball stud on the right cylinder head cover until the rubber grommet is fully seated (Figure 21).
23. Install the bolt securing the resonator to the intake manifold and tighten to 3.5 N.m (31 In. Lbs.) (Figure 21).
24. Lubricate the rubber grommets on the engine cover with Mopar® Rubber Bushing Installation Lube.
25. Align the rubber grommets of the engine cover to the ball studs and press firmly downwards (Figure 20).
26. Install the bolts securing the engine cover to the intake manifold and tighten to 10 N.m (7 Ft. Lbs.) (Figure 20).
27. Measure the isolation resistance at the Power Inverter Module (PIM) between the positive high voltage terminal and chassis ground. Also between the negative high voltage terminal and chassis ground. The measured isolation resistance should be greater than 1.1 MΩ and less than 10 MΩ. Compare these isolation resistance values with those taken during High-Voltage Power-Down to verify the integrity of the repair. Typically, the measured isolation resistance for this vehicle is between 7.7 MΩ and 8.6 MΩ.
    • If the measured isolation resistance is between 7.8 MΩ and 8.6 MΩ, it is safe to continue the High Voltage Power Up procedure.
    • If the measured isolation resistance is outside of the 7.8 MΩ and 8.6 MΩ range, a loss of isolation condition exists within the high-voltage circuitry. Do not continue the High Voltage Power Up procedure until the condition causing the loss of isolation is corrected.
28. Install the new  PIM high voltage terminal cover and tighten the five captured screws to 7.8 N.m (69 In. Lbs.) (Figure 14).
    CAUTION: Ensure the cover gasket is properly seated in the groove prior to assembly onto the PIM. If not seated properly, the gasket will be damaged when the cover fasteners are tightened.
29. Install the single High Voltage Inter-Lock (HVIL) connector to the PIM cover and tighten the two captive screws to 7.8 N.m (69 In. Lbs.) (Figure 13).
30. Remove the safety cover from the high-voltage battery receptacle (Figure 9).
31. Inspect the mounting interface surface of the high-voltage Manual Service Disconnect (MSD) and the receptacle wall to ensure they are clean, and that there are no surface contaminants or foreign objects within the receptacle (Figure 8).
32. Align the polarization feature of the high-voltage manual service disconnect with the receptacle on the high-voltage battery (Figure 8).
33. Push the high-voltage manual service disconnect evenly into the receptacle with the lever in the upright 90° position.
    NOTE: With the high-voltage manual service disconnect properly aligned with the receptacle, the lever will be released and allowed to rotate to the lock position. Do not force the lever.
34. Rotate the lever while maintaining a slight force on the high-voltage manual service disconnect. The lever will engage the receptacle and draw the high-voltage manual service disconnect down onto the receptacle as the lever is rotated (Figure 42).
35. Rotate the lever downward until it is fully engaged and locked by the lever release latch. An audible "click" will be heard as the lever latches into position (Figure 42).
36. Gently pull the high-voltage manual service disconnect upward to ensure that it is fully seated in the receptacle and locked. If the manual service disconnect can be removed, repeat steps 33 - 34  .
37. Position the high-voltage manual service disconnect access cover over the floor opening. Install the four retaining screws and tighten to 2.5 N.m (22 In. Lbs.) (Figure 5).
    NOTE: The clearance between the top of the high-voltage manual service disconnect and the bottom of the access cover is such that the access cover will not seat properly on the floor if the high-voltage service disconnect is not fully seated.
38. Install the carpet and floor mat over the high-voltage manual service disconnect access cover (Figure 4).
39. Install the coolant inlet and outlet hoses to the PIM and position the clamps (Figure 19). The PIM coolant upper fitting is outlet and lower fitting is inlet.
40. Remove the hose-pinching pliers from the coolant inlet and outlet hoses (Figure 19).
41. Lubricate the air cleaner body rubber mounting sockets with Mopar® Rubber Bushing Installation Lube.
42. Install the air cleaner body straight down until the locating pins engage with the rubber mounting sockets are fully seated (Figure 12).
43. Install the air inlet duct and engage the locating pins (Figure 12).
44. Tighten the air inlet duct to air cleaner body clamp to 5 N.m (44 In. Lbs.) (Figure 12).
45. Install the air cleaner element into the air cleaner housing (Figure 11).
46. Install the air cleaner housing cover onto the air cleaner housing. Tighten the cover retaining screws to 5 N.m (44 In. Lbs.) (Figure 10).
47. Tighten the clean air tube clamp at the resonator to 5 N.m (44 In. Lbs.) (Figure 10).
48. Connect the wire harness connector to the Inlet Air Temperature (IAT) sensor (Figure 10).
49. Connect the fresh air makeup hose to the air cleaner body (Figure 10).
50. Remove the protective cover 10084 from the 12-volt positive battery cable (Figure 3).
51. Connect the positive battery cable to the 12-volt Power Distribution Center (PDC) and tighten the nut to 9 N.m (80 In. Lbs.) (Figure 2).
52. Install the 12-volt PDC cover (Figure 1).
53. Raise and support the vehicle.
54. Install the engine belly pan to the vehicle and secure with the push pin fastener (Figure 17).
55. Install eight silver M6 screws attaching the belly pan front belly pan. Tighten the screws to 6 N.m (53 In. Lbs.) (Figure 17).
56. Install four black M4.8 screws attaching the wheelhouse splash shields to the engine belly pan. Tighten the screws to 2.8 N.m (25 In. Lbs.) (Figure 17).
57. Install the front belly pan to the vehicle and secure with two push-pin fasteners (Figure 16).
58. Install the eight silver M6 screws attaching the front belly pan to the vehicle. Tighten the screws to 6 N.m (53 In. Lbs.) (Figure 16).
59. Install four black M4.8 screws attaching the wheelhouse splash shields to the front belly pan. Tighten the screws to 2.8 N.m (25 In. Lbs.) (Figure 16).
60. Install six black M4.8 screws attaching the front belly pan to front fascia. Tighten the screws to 2.8 N.m (25 In. Lbs.) (Figure 16).
61. Lower the vehicle.
    NOTE: The replacement PIM contains generic bootloader software and must be flashed with latest software release available on wiTECH before the module or vehicle will function.
62. Proceed now to Page 41, Section D. Reprogram Multiple Control Modules  and complete the software reprogramming steps for all modules before continuing with the next step of this procedure.
    NOTE: The following wiTECH screen image is an example of a newly installed PIM with bootloader software causing the Auxiliary Hybrid Control Processor (AHCP) to display solid red (Figure 43). It is normal for a blank PIM with generic Bootloader software to cause the AHCP to display solid red. This indicates that the PIM is not communicating on the Controller Area Network (CAN) bus. There is nothing wrong with this PIM, therefore continue with the software flash procedure.
63. Add MS.12106 engine coolant to the power electronics cooling system pressurized coolant reservoir through the filler neck until the coolant level reaches the MAX level of the coolant reservoir (Figure 44).
    CAUTION: Only deionized or distilled water can be used in the PHEV cooling systems. The use of tap water is prohibited as this can damage the components.
    NOTE: A 50/50 mixture of an ethylene glycol based antifreeze formulated with Organic Acid Technology (OAT) and deionized or distilled water is required such as Mopar® US - 68163849AB, Canada - 65175339AC 50/50 Prediluted Antifreeze/Coolant or equivalent meeting the requirements of FCA Material Standard MS.12106.
64. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge.
65. Connect the wiTECH micro pod II to the vehicle data link connector
66. Place the ignition in the "RUN  " position.
67. Open the wiTECH 2.0 website.
68. Enter your "User id  " your "Password  " and your "Dealer Code  ", then select "Finish  " at the bottom of the screen.
69. Starting at the "Vehicle Selection  " screen, select the appropriate vehicle.
70. From the "Action Items  " screen, select the "Topology  " tab.
71. From the "Topology  " tab, select the "HCP  " icon.
72. From the "HCP  " screen, select the "MISC functions  " tab.
73. From the "MISC functions  " tab, select "Low Temp Coolant Fill - Passive  " then follow the wiTECH screen instructions to complete the routine.
74. Monitor the reservoir coolant level for the next 5 minutes and add additional coolant if required to maintain the minimum indicated coolant level.
    NOTE: Do not allow the coolant reservoir to empty while running this routine.
75. Allow the coolant level to stabilize for 30 seconds. If the coolant level drops during the stabilization period, and no leaks are present, repeat fill process.
76. Add engine coolant through the reservoir filler neck as required until the coolant level reaches the MAX level of the PIM coolant reservoir. Tighten the cap on the pressurized coolant reservoir.
77. Switch ignition to the OFF position.
78. Using Mopar® SVT275 Cooling Pressure Tester or an equivalent, pressure test the PIM coolant system and check for leaks.
79. Raise the vehicle until the front tires are approximately 30 cm (12 in.) from the ground.
80. Enter the vehicle and make sure the vehicle doors are closed to prevent the Automatic Shift to Park function from engaging during the test.
81. Switch off the Electronic Stability Control (ESC), if equipped.
82. Place the ignition in the "RUN  " position.
83. From the wiTECH "Action Items  " screen, select the "Topology  " tab.
84. From the "Topology  " tab, select the "HCP  " icon.
85. From the "HCP  " screen, select the "MISC functions  " tab.
86. From the "MISC functions  " tab, select "Resolver Offset Learn  " then follow the wiTECH screen instructions to complete the routine.
87. Obtain the vehicle key code:
    1. Sign into Dealer Connect.
    2. Select the "Service  " Tab.
    3. From the "Repair Information  " section, select "Key Code  ".
    4. On the "Key Code Inquiry Criteria  " screen, enter the vehicle "VIN  ", "Reason Code  " 3-Vehicle Repair, "Password  ", and accept the "Dealer Policy  " agreement.
    5. Record the 4-digit authorization PIN number for use during the "Immobilizer ECUs Replaced  " routine.
    NOTE: The vehicle key code will be required for the Launch Immobilizer ECUs Replaced routine.
88. From the "Action Items  " screen, select the "Topology  " tab.
89. From the "Topology  " tab, select the "BCM  " icon.
90. From the "BCM  " screen, select the "MISC functions  " tab.
91. From the "MISC functions  " tab, select "Immobilizer ECUs Replaced  " then follow the wiTECH screen instructions to complete the routine.
    NOTE: The vehicle key code will be required during the Launch Immobilizer ECUs Replaced routine.
92. Select the "Clear All DTCs  " tab, then click "Clear All DTCs  " and then select "Close  ".
93. Create and save a Vehicle Scan Report (VSR) before proceeding. Both pre and post scan reports will be required  for submission to warranty.
    1. From the left column in the analysis section, select "Reports  ".
    2. On the reports page, select "Scan Report  ".
    3. Select "ECU Summary  " from the dropdown menu on the right.
    4. Select "Printer Friendly  " then save file type as "PDF  ". Name the file with the last eight digits of the vehicle VIN.
94. Turn the ignition to the "OFF  " position and then remove the wiTECH micro pod II device from the vehicle.
95. Lower the vehicle.
96. Remove the battery charger from the vehicle.
97. Return the vehicle to the customer.
98. Complete proof of correction form for California Residents.

D. REPROGRAM MULTIPLE CONTROL MODULES

1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge.
2. Connect the wiTECH micro pod II to the vehicle data link connector
3. Place the ignition in the "RUN  " position.
   NOTE: The following procedure steps are based on using the wiTECH 2.0 scan tool. If an earlier version of the wiTECH scan tool is used, procedure steps may be different.
4. Open the wiTECH 2.0 website.
5. Enter your "User id  " your "Password  " and your "Dealer Code  ", then select "Finish  " at the bottom of the screen.
6. Starting at the "Vehicle Selection  " screen, select the vehicle to be updated.
7. Create and save a Vehicle Scan Report (VSR) before proceeding. Both pre and post scan reports will be required  for submission to warranty.
   1. From the left column in the analysis section, select "Reports  ".
   2. On the reports page, select "Scan Report  ".
   3. Select "ECU Summary  " from the dropdown menu on the right.
   4. Select "Printer Friendly  " then save file type as "PDF  ". Name the file with the last eight digits of the vehicle VIN.
   NOTE: The PIM contains two processors, Hybrid Control Processor (HCP) and Auxiliary Hybrid Control Processor (AHCP). The HCP and AHCP are combined into one PIM software update. The software update must begin with updating the HCP. The AHCP will update immediately following the HCP.
8. From the "Action Items  " screen, select the "All Flashes  " tab.
   • Select "HCP  " by clicking the arrow on the right side of the screen. Read the special flash instructions, then select "OK  ". Continue with Step 9  .
   • If "HCP  " is not displayed as one of the available flashes, the PIM software is already at the current software level and does not require updating. Proceed to Step 11  .
9. From the "Flash ECU Agreement  " page, agree to terms by "Checking the Box  ".
10. Select "Flash ECU  " and then follow the wiTECH screen instructions to complete the flash.
11. Once the software is confirmed to be at the latest available calibration level, select "View DTCs  ".
12. Select the "Clear All DTCs  " tab, then click "Clear All DTCs  " and then select "Close  ".
13. From the "Action Items  " screen, select the "All Flashes  " tab.
    • Select "PCM  " by clicking the arrow on the right side of the screen. Read the special flash instructions, then select "OK  ". Continue with Step 14  .
    • If "PCM  " is not displayed as one of the available flashes, the PCM software is already at the current software level and does not require updating. Proceed to Step 18  .
14. From the "Flash ECU Agreement  " page, agree to terms by "Checking the Box  ".
15. Select "Flash ECU  " and then follow the wiTECH screen instructions to complete the flash.
16. Once the software is confirmed to be at the latest available calibration level, select "View DTCs  ".
17. Select the "Clear All DTCs  " tab, then click "Clear All DTCs  " and then select "Close  ".
18. From the "Action Items  " screen, select the "All Flashes  " tab.
    • Select "BPCM  " by clicking the arrow on the right side of the screen. Read the special flash instructions, then select "OK  ". Continue with Step 19  .
    • If "BPCM  " is not displayed as one of the available flashes, the BPCM software is already at the current software level and does not require updating. Proceed to Step 23  .
19. From the "Flash ECU Agreement  " page, agree to terms by "Checking the Box  ".
20. Select "Flash ECU  " and then follow the wiTECH screen instructions to complete the flash.
21. Once the software is confirmed to be at the latest available calibration level, select "View DTCs  ".
22. Select the "Clear All DTCs  " tab, then click "Clear All DTCs  " and then select "Close  ".
23. From the "Action Items  " screen, select the "All Flashes  " tab.
    • Select "OBCM  " by clicking the arrow on the right side of the screen. Read the special flash instructions, then select "OK  ". Continue with Step 24  .
    • If "OBCM  " is not displayed as one of the available flashes, the OBCM software is already at the current software level and does not require updating. Proceed to Step 28  .
24. From the "Flash ECU Agreement  " page, agree to terms by "Checking the Box  ".
25. Select "Flash ECU  " and then follow the wiTECH screen instructions to complete the flash.
26. Once the software is confirmed to be at the latest available calibration level, select "View DTCs  ".
27. Select the "Clear All DTCs  " tab, then click "Clear All DTCs  " and then select "Close  ".
    NOTE: An additional key cycle may be necessary to move active DTCs to stored DTCs then it will be necessary to clear all DTCs again.
28. If PIM was replaced  , return now to Page 37, Step 63 of Section C. Power Inverter Module (PIM) Installation  to perform PHEV cooling system purge and Immobilizer learn procedures. If the PIM was not replaced  , continue with the next step.
29. Create and save a Vehicle Scan Report (VSR) before proceeding. Both pre and post scan reports will be required  for submission to warranty.
    1. From the left column in the analysis section, select "Reports  ".
    2. On the reports page, select "Scan Report  ".
    3. Select "ECU Summary  " from the dropdown menu on the right.
    4. Select "Printer Friendly  " then save file type as "PDF  ". Name the file with the last eight digits of the vehicle VIN.
30. Turn the ignition to the "OFF  " position and then remove the wiTECH micro pod II device from the vehicle.
31. Remove the battery charger from the vehicle.
32. Return the vehicle to the customer.
33. Complete proof of correction form for California Residents.